Training Guidance For Construction Workforce Inspectors Final

Final October 26, 2012
Pipeline Construction:
Quality Issues and Solutions Action Plans

Training Guidance for Welding & Coating
Workers & Inspectors
The INGAA Foundation | Pipeline Training Guidance for Welding & Coating Workers & Inspectors i

Training Guidance for Welding & Coating
Workers & Inspectors

Table of Contents
Team Members .................................................................................................................................. ii
Summary and Introduction.................................................................................................................1
Table 1 | Welding QA/QC ITP .................................................................................................2
Table 2 | Weld Joint / Pipe Coating QA/QC ITP ...................................................................................4
Table 3 | Tie In Coating Transition Area QA/QC ITP .............................................................................6
Welding QA/QC ITP Pocket Guide ....................................................................................................8
Weld Joint / Pipe Coating QA/QC ITP Pocket Guide ..........................................................................9
Tie In Coating Transition Area QA/QC ITP Pocket Guide .................................................................. 10
Table 4 | Issues Identified During PHMSA Inspection of 35 Construction Projects .............................. 11

The INGAA Foundation | Pipeline Training Guidance for Welding & Coating Workers & Inspectors ii

Team Members
Paul R Amato, Iroquois Pipeline, Group Lead
Tarry Hutton, NiSource
David McMurray, Wilcrest
Cliff McPherson, Panhandle
Craig Meier, Sunland Construction
Kirk Peterman, Panhandle

The INGAA Foundation | Pipeline Training Guidance for Welding & Coating Workers & Inspectors 1

Summary and Introduction
Construction specifications, establish specific requirements for completing field construction activities in
a manner compliant with codes and the Operators special requirements. However, these specifications and
procedures are lengthy documents often written in contract language. As a result, contractors and
operators often develop their own interpretations and documentation to train skilled construction workers.
As an outcome of the INGAA Foundations October 15, 2009 Pipeline Construction, Fabrication, Testing
Workshop these guidelines were developed. The objective of this guideline is to develop simple but
effective training guidance for construction management and workers to ensure consistent and compliant
construction practices. These guidelines identify some minimum general key elements that should be
considered during construction inspections. Project specific requirements should still be followed. Tables
1, 2 and 3 provide inspection guidance templates that align with these elements to assist the inspectors as
follows:
Table 1 is an inspection and test plan (ITP) for QA/QC of welders and weld inspection.
Table 2 is an ITP guidance document on key QA/QC elements for weld joint and pipe coating workers
and inspectors;
Table 3 is an ITP guidance document for QA/QC for tie-in coating transition areas; and
Pocket guides for tables 1, 2 and 3 have been developed for printing and easy use in the field by welding
and coating workers and inspectors. These are attached.
Table 4 is a listing of the construction, coating and welding inspection issues compiled by PHMSA during
its inspection of 35 projects. The issue areas in this table relate to PHMSAs determinations and are an
important advisory to welding and coating workers and inspectors.
These Key Elements / Templates may be used as a check list or reminder to verify an understanding of
the key issues and associated documentation, where needed, is complete for those issues. For example,
Operator Qualification (OQ) requirements are mentioned. Although this white paper does not specify
the OQ documentation requirements, the intent is to remind inspectors they should review the necessary
OQ documentation for each project to ensure they are adequate (e.g. there already is a Field Verification
Report). Therefore this document is not intended to place additional documentation burdens but remind
the inspector to check OQ paperwork.
It also should be noted these key elements are not to replace the complete project specific
documentation. They are intended to be focus points and / or simple guides to be used. The Acceptance
Criteria are guidelines to be used in the absence of Company specific requirements. They are not an
effort to supersede or establish existing criteria. The Project Procedure and applicable codes & standards
are to be used for actual criteria for the specific projects.
The following pages provide an example of Key Elements / Templates for Welding and Field Applied
Coating.

Table 1 | Welding QA/QC ITP (Page 1 Rev. 0)
Item
No.
Activity Project
Welding
Procedure

Frequency Acceptance Criteria Project Responsibilities Action/Record
Contractor
Responsibility
(QC)
Operator
Responsibility
(QA)
1 Safety JSA Safety Manual Daily
1
Ensure ALL employees
are wearing proper PPE
for the relevant task at
hand
X

X Tailgate safety
1

Appropriate P.P.E
Complete & sign JSA
2 Verify Weld
Procedure

Project Welding
Manual
As needed Applicable weld
procedure
Correct WPS and PQR
for weld
X X Determine proper weld procedure
& notify welders
Verify WPS applies to essential
variables
Welder Foreman Report
3 Verify Qualified
Welders
Operator
Specification
Prior to welding
Change of
Welder and/or
Procedure
Welder Qualification
Log
Verify Operator
Qualification
Requirements (as
applicable)
X X Verify welders qualified to
procedure per Welder
Qualification Log
Field Verification Report or similar
(as needed)
4 Pipe Inspection Operator
Specification
Each joint Pipe free of debris X -- Swab each joint
No record
5 Bevel Prep Weld Procedures Each joint Clean bevel per
Weld Procedure
X X Buff bevel
No record
6 Pre heat Weld Procedures Each joint Minimum as specified
and verified by temp
stick or equivalent.
X X Pre heat bevel
No record
Temp stick
7 Line up Weld Procedures Each joint Root opening 1/16
Seams 2-4 offset
High-low 1/16 &
Weld Procedure
X X Appropriate use of line up clamp
No record
8 Inter-pass
Temperature
Weld Procedures Each joint Minimum as specified
and verified by temp
stick or equivalent.
X X Temp stick
1
Any employee that does not attend the morning JSA/Safety tailgate, needs to review and sign, prior to working

Table 1 (Continued) (Page 2 Rev. 0)
Item
No.
Activity Project
Welding
Procedure

Frequency Acceptance Criteria Project Responsibilities Action/Record
Contractor
Responsibility
Representative
Responsibility
9

Speed of
Travel
2

Weld
Procedures
As Needed Range is inches/min
per WPS/PQR
-- X Stopwatch
10 Amperage
2
Weld
Procedures
As Needed Range is amps per
WPS/PQR
-- X Multi meter
11 Volt
2
Weld
Procedures
As Needed Range Volts per WPS -- X Multi meter
12

Repair of
Defects-
Cracks/Arc
Burns
Repair
Procedure
As Needed Welding Inspector approval

X X Visual and NDE Inspection
NDE report NDE
Visual.
Specific procedure for repair on
repair if allowed by Operator
13 Field
Transitions
Operator
Specification
As Needed Per operator
specification depending
on < or > 20% specified
yield strength
X X Visual and NDE Inspection
NDE report
14 Weld
Acceptance
Weld
Procedures
& NDE
Procedure
Each weld API 1104
B31.8
NDE Procedures
-- X Visual and NDE Inspection
NDE report

15 Check
consumables
and Welding
Equipment
Operator
Specification
Daily Proper consumable
storage
Welding equipment in
proper condition
X X No record
2
Note: travel, amperage and volts vary for bead, hot pass and filler passes (inform welders to follow WPS)


Table 2 | Weld Joint / Pipe Coating QA/QC ITP (Page 1 Rev. 0)
Item
No.
Activity Project
Procedure
Frequency Acceptance Criteria Contractor
Responsibility
(QC)
Operator
Responsibility
(QA)
Action/Record
1

Safety JSA
Prior to
performing ANY
duties the
coating foreman
must ID ALL
Hazards
Safety Manual Daily
1

Ensure ALL employees are
wearing proper PPE for the
relevant task at hand
X X Tailgate safety
1

Appropriate P.P.E (Including: Blasting
Hood/Fresh Air Canister/Air Lines)
Complete & sign JSA
2 Applicator
qualifications
Manufacturers
Specifications
Per Project Understanding of
manufacturing
installation techniques
Verification of Operator
Qualification as
applicable
X X Demonstrates knowledge of
manufacturing installation methods /
techniques
Field Verification report or equivalent
3 Inspection &
Surface
prep,
Weld Joint

Documentation -
2 per shift
(minimum)
Inspection per
occurrence

Test Pipe to see if non-
visible contaminates
exist. Clean as per
Operator specification.
Blasted to a NEAR
WHITE finish
Surface Profile will be
checked and
documented
X X Inspect & Examine pipe for non-visible
contaminates.
Blast and check profile
Remove all Frayed/Loose coating near
cutback
Brush Blast existing FBE
Daily coating foreman report.
4 Coating
Application
Weld Joint

Documentation -
2 per shift
(minimum)
Application per
occurrence

As per application
specification. Pipe
temperature should be
5 degrees above dew
point.
Pre-heat pipe as per
specification
X X Document temperatures
Do not handle, lower in, or backfill until
completely cured
Measure dew point temperature,
surface preparation, relative humidity,
pipe temperature and mill thickness
Daily coating foreman report
1


Item
No.
Activity Project
Procedure
Responsibility
(QC)
Operator
Responsibility
(QA)
Action/Record
5

Pipe Coating
Inspection
Weld Joint / Pipe
Coating

Each joint No damage
All coated pipe shall be tested
to locate holidays. After the
holidays are patched, and just
before pipe is lowered into the
ditch-- reinspect.
Check for appropriate coating
thickness.
Utilize holiday detector with
voltage setting (FBE 2,000
volts DC, dual coat & two part
epoxy 100 volts DC per mil of
coating) shall be verified.
The holiday detectors batteries
must be checked daily and
replaced/recharged if required.
Calibrate holiday detector daily
X X Visual Inspect
Jeep
6 Coating repair Weld Joint/Pipe
Coating
As needed Repair with patch stick, epoxy gun
or two part epoxy in accordance
with Operator specifications.
X X Record as per operator
requirements
7

Storage & Handling Operator
Specification
Daily Maintained and stored in
accordance with manufacturing
specifications.
X -- Ensure proper Storage
- Any employee that does not attend the morning JSA/Safety tailgate, needs to review and sign, prior to working

Table 3 | Tie In Coating Transition Area QA/QC ITP (Page 1 Rev. 0)
Item
No.
Activity Project
Procedure
Responsibility
(QC)
Operator
Responsibility
(QA)
Action/Record
1

Safety JSA
Prior to performing
ANY duties the
coating foreman
must ID ALL
Hazards
Safety Manual Daily
1

X X Tailgate safety
1

Appropriate P.P.E
(Including: Blasting
Hood/Fresh Air Canister/Air
Lines)
Complete & sign JSA
Excavation safety review
2 Applicator
qualifications
Manufacturers
Specifications
Per Project Understanding of
manufacturing installation
techniques
Verification of Operator
Qualification as applicable
X X Demonstrates knowledge of
methods / techniques
Field Verification report or
equivalent
3 Inspection & Surface
preparation,
Transition Area
from existing to
new coating

Documentation
- 2 per shift
(minimum)

Inspection
per occurrence

Test Pipe to see if non-visible
contaminates exist. Clean as
per Operator specification.
Blasted to a NEAR WHITE
finish
Surface Profile will be checked
and documented
X

X Inspect & Examine pipe for
non-visible contaminates.
Blast and check profile
Remove all Frayed/Loose
coating near cutback
4 Coating Application Transition from
existing to new
coating

Documentation
- 2 per shift
(minimum)

Application
per occurrence

As per application
specification. Pipe
temperature should be 5
degrees above dew point.
Pre-heat pipe as per
specification. Pipe
temperature should be 5
degrees above dew point
Overcoat per operator
specification
X X Document temperatures
Do not handle, lower in, or
backfill until completely
cured
Measure dew point
temperature, surface
preparation, relative
humidity, pipe temperature
and mill thickness
1

5 Pipe Coating
Inspection
Weld Joint

Each weld No damage
All coated pipe shall be tested
to locate holidays. After the
holidays are patched, and just
before pipe is lowered into the
ditch-- reinspect.
Check for appropriate coating
thickness.
Utilize holiday detector with
voltage setting (FBE 2,000
volts DC, dual coat & two part
epoxy 100 volts DC per mil of
The holiday detectors batteries
must be checked daily and
replaced/recharged if required.
X X Visual Inspect
Jeep
6 Coating repair Weld Joint

As needed Repair with patch stick, epoxy gun
or two part epoxy in accordance
with Operator specifications.
X X Record as per operator
requirements
7

Storage & Handling Operator
Specification
Daily Maintained and stored in
accordance with manufacturing
specifications.
X -- Ensure proper Storage
1


Welding QA/QC ITP Pocket Guide

Welding QA/QC ITP Pocket Guide
Activity
Project Welding
Procedure
Frequency Acceptance Criteria Action / Record
Safety JSA Safety Manual Daily
Tailgate safety
Appropriate PPE
Complete & sign JSA
Verify Weld
Procedure
Project Welding
Manual
As needed
Applicable weld procedure
Determine proper weld
procedure & notify welders
Correct WPS and PQR for weld
Verify WPS applies to
essential variables
Verify Qualified
Welders
Complete Section
Prior to welding Welder Qualification Log
Verify welders qualified to
procedure per Welder
Qualification Log
Change of
Welder and/or
Procedure
Verify Operator Qualification
Requirements (as applicable)
Field Verification Report or
similar (as needed)
Pipe Inspection

Each joint Pipe free of debris
Swab each joint
No record
Bevel Prep Weld Procedures Each joint Clean bevel per Weld Procedure
Buff bevel
No record
Pre heat Weld Procedures Each joint
Minimum of 250 F Verified by
temp stick or equal.
Pre heat bevel
No record
Temp stick
Line up Weld Procedures Each joint
Root opening 1/16 Use of line up clamp
Seams 2-4 offset
No record
High-low 1/16 & Weld Procedure
Time between
Bead/Root & Start
of hot pass/2nd
Bead
Weld Procedures Each joint Max time is 5 minutes Stopwatch

Welding QA/QC ITP Pocket Guide Page 2
Activity
Project Welding
Procedure
Frequency Acceptance Criteria Action / Record
Speed of Travel Weld Procedures Each joint Range is inches/min per WPS / PQR Stopwatch
Amperage Weld Procedures Each joint Range is amps per WPS/PQR Multi meter
Volt Weld Procedures Each joint Range Volts per WPS Multi meter
Max time between
End of Hot Pass &
Start of other
Weld Procedures As Needed Per operator specification
Record as per operator
requirements
Repair of Defects,
Cracks / Arc Burns
Repair Procedure As Needed Welding Inspector Approval
Visual and NDE
Inspection
NDE report NDE
Visual.
Specific procedure for
repair on repair if allowed
by Operator
Field Transitions
Operator
Specification
As Needed
Per Stated Procedure depending on <
or > 20% specified yield strength
Visual and NDE
Inspection
NDE report
Weld Acceptance
Weld Procedures
Each weld
API 1104
Visual and NDE
Inspection
& NDE Procedure B31.8
NDE report
NDE Procedures
Check consumables
and Welding
Equipment

Daily
Proper consumable storage
requirements
Welding equipment in proper condition


Weld Joint / Pipe Coating QA/QC ITP Pocket Guide

Weld Joint / Pipe Coating QA/QC ITP Pocket Guide
Activity Project Procedure Frequency Acceptance Criteria Action / Record
Safety JSA
Safety Manual
Daily
Ensure ALL employees are wearing proper
PPE for the relevant task at hand
Tailgate safety
Prior to
performing ANY
duties the coating
foreman must ID
ALL Hazards
Appropriate PPE (Including:
Blasting Hood/Fresh Air
Canister/Air lines)
Complete & sign JSA
Applicator
qualifications
Manufacturers
Specifications
Per Project
Understanding of manufacturing
Demonstrates knowledge of
Verification of Operator Qualification as
applicable
equivalent
Inspection &
Surface
preparation
Weld Joint
Documentation -2 per
shift (minimum)
contaminates exist. Clean as per Operator
specification.
Inspect & Examine pipe for
Inspection per
occurrence
Blasted to a NEAR WHITE finish Blast and check profile
Surface Profile will be checked and
documented
Coating
Application
Weld Joint
shift (minimum)
As per application specification. Pipe
temperature has to be 5 degrees above
dew point.
Document temperatures
Application per
occurrence
Pre-heat pipe as per specification
backfill until completely cured
Measure dew point
preparation, relative humidity,
pipe temperature and mill
thickness

Weld Joint / Pipe Coating QA/QC ITP Pocket Guide Page 2
Pipe Coating
Inspection
Weld joint / pipe
coating
Each joint
No damage Visual Inspect
All coated pipe shall be tested to locate
holidays. After the holidays are patched,
and just before pipe is lowered into the
ditch--reinspect.
Jeep
Check for appropriate coating thickness.
Utilize holiday detector with voltage setting
(FBE 2,000 volts DC, dual coat & two part
epoxy 100 volts DC per mil of coating)
shall be verified.
The holiday detectors batteries must be
checked and replaced/recharged if required
daily.
Coating repair
Weld joint / pipe
coating
As needed
Repair with patch stick, epoxy gun or two
part epoxy in accordance with Operator
specifications.
requirements
Storage &
Handling
Weld joint / pipe
coating
Daily
Maintained and stored in accordance with
manufacturing specifications.
Ensure proper Storage


Tie In Coating Transition Area QA/QC ITP Pocket Guide

Tie In Coating Transition Area QA/QC ITP Pocket Guide
Safety JSA
Safety Manual Daily
Ensure ALL employees are wearing proper
PPE for the relevant task at hand
Tailgate safety
Prior to performing
ANY duties the coating
foreman must ID ALL
Hazards
Appropriate PPE (Including:
Blasting Hood/Fresh Air
Canister/Air Lines)
Complete & sign JSA
Excavation safety review
Applicator
qualifications
Manufacturers
Specifications
Per Project
Understanding of manufacturing
Demonstrates knowledge of
Verification of Operator Qualification as
applicable
equivalent
Inspection & Surface
prep
Transition Area from
existing to new
coating
shift (minimum)
contaminates exist. Clean as per Operator
specification.
Inspect & Examine pipe for
Inspection per
occurrence
Blasted to a NEAR WHITE finish Blast and check profile
Surface Profile will be checked and
documented
Coating Application
Transition from
existing to new
coating
shift (minimum)
As per application specification. Pipe
dew point.
Document temperatures
Overcoat will start and finish a
minimum distance away from the
transition area
Application per
occurrence
Pre-heat pipe as per specification Pipe
dew point
backfill until completely cured
Overcoat per operator specification
Measure dew point
preparation, relative humidity,
pipe temperature and mill
thickness

Tie In Coating Transition Area QA/QC ITP Pocket Guide Page 2
Pipe Coating
Inspection

Each weld
No damage Visual Inspect
All coated pipe shall be tested to locate
holidays. After the holidays are patched,
and just before pipe is lowered into the
ditch.
Jeep
Check for appropriate coating thickness.
Utilize holiday detector with voltage setting
(FBE 2,000 volts DC, dual coat & two
part epoxy 100 volts DC per mil of
The holiday detectors batteries must be
checked and replaced/recharged if
required daily.
Coating repair Weld Joint As needed
Repair with patch stick, epoxy gun or two
part epoxy in accordance with Operator
specifications.
requirements
Storage & Handling

Daily
Maintained and stored in accordance with
manufacturing specifications.
Ensure proper Storage


Table 4 | Issues Identified During PHMSA Inspection of 35 Construction Projects

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Final October 26, 2012

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